Bracket for anti-lock braking system sensor

ABSTRACT

A bracket for securely positioning an anti-lock braking system sensor on a heavy-duty vehicle axle adjacent to wheel hub tone ring teeth is formed from a single piece of robust material such as sheet steel. A steel blank of a certain size and shape preferably is stamped from the sheet steel and is formed by a multi-stage process into the final bracket configuration. The bracket includes a tubular portion formed with a continuous opening for receiving the sensor and a retaining sleeve. A pair of spaced-apart, parallel rearwardly extending bracket feet ensure proper positioning of the sensor relative to the tone ring teeth, and enable use of the bracket in various applications having different wheel hub and/or axle spindle configurations.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The invention relates to means for mounting an anti-lock brakingsystem sensor, hereinafter referred to as an “ABS” sensor, adjacent to atone ring of a wheel hub, and in particular to a bracket for mountingthe ABS sensor on an axle of a heavy-duty vehicle such as a semi-traileror straight truck. More particularly, the invention is directed to anABS sensor bracket made by forming a single piece of robust materialinto a tubular configuration for locating a retaining sleeve and the ABSsensor in a proper position relative to the wheel hub for sensingrotation of the hub tone ring teeth, thereby eliminating the need formore costly brackets heretofore formed by casting, machining, orfabrication and welding of multiple parts.

[0003] 2. Background of the Invention

[0004] In recent years, anti-lock braking systems, more commonlyreferred to as ABS, have become common safety equipment on every type ofvehicle ranging from cars to semi-trailers. In heavy-duty vehicles suchas straight trucks and semi-trailers, government regulations require atleast one axle of the tandem axles commonly found on such vehicles, toinclude an ABS sensor on each end of that axle. Some manufacturers ofsuch heavy-duty vehicles go beyond government regulations and includethe ABS sensors on every axle to improve ABS performance.

[0005] Each ABS sensor must be located adjacent to the inboard facingside of the wheel hub which incorporates a tone ring having teeth formedthereon. As is well-known to those skilled in the art, such sensorsdetect certain movements of the teeth on the tone ring, which in turncauses an electrical signal to be sent to the ABS electronic controlunit enabling control of brake engagement. Thus, it is important thatthe ABS sensor be precisely positioned on the vehicle axle inboardlyadjacent to and aligned with the tone ring teeth so that it can properlyperform its sensing function.

[0006] Prior art brackets which attach to the axle and position the ABSsensor adjacent to the wheel hub tone ring have heretofore been made inone of three ways. Specifically, such brackets either typically werecast, formed from heavy blocks of metal by machining, or made frommultiple parts which required fabrication and welding to form thebracket. Each of these methods of forming an ABS sensor bracket carrieda cost penalty. Moreover, a custom bracket design generally had to bemade for each application having a different wheel hub and/or spindleconfiguration. For example, one design might be required for a taperedspindle and another design for a straight spindle.

[0007] The present invention solves the cost problem associated withprior art ABS sensor brackets by forming the bracket from a single pieceof robust material such as sheet steel which can be efficiently foldedinto a generally tubular-shaped bracket for holding the ABS sensor inits proper position on the vehicle axle adjacent to the wheel hub tonering. The present invention bracket design carries the additionaladvantage of being useful on different wheel hub and/or spindleapplications.

SUMMARY OF THE INVENTION

[0008] Objectives of the present invention include providing a bracketfor an ABS sensor which can be manufactured relatively inexpensively.

[0009] Another objective of the present invention is to provide such anABS sensor bracket which enables easy mounting of the ABS sensor, andwhich itself is easily mounted on a vehicle axle adjacent to a wheel hubtone ring.

[0010] Yet another objective of the present invention is to provide suchan ABS sensor which is useful with various wheel hub and/or spindleconfigurations.

[0011] Still another objective of the present invention is to providesuch an ABS sensor bracket which is relatively lightweight, durable inuse, easy to maintain and replace, and can be economically produced inlarge volumes.

[0012] These objectives and advantages are obtained by the bracket ofthe present invention for positioning sensor means on a vehicle axleadjacent to a wheel hub tone ring, the general nature which may bestated as including, means for capturing the sensor means, and at leastone foot attached to the capture means for contacting an exteriorsurface of the axle to insure proper location of the sensor means on theaxle adjacent to the wheel hub tone ring for sensing movement of thetone ring.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The preferred embodiment of the invention, illustrative of thebest mode in which applicants have contemplated applying the principles,is set forth in the following description and is shown in the drawingsand is particularly and distinctly pointed out and set forth in theappended claims.

[0014]FIG. 1 is a rear-end perspective view of the ABS sensor bracket ofthe present invention;

[0015]FIG. 2 is a front-end perspective view of the ABS sensor bracketshown in FIG. 1;

[0016]FIG. 3 is a front-end view of the ABS sensor bracket of FIGS. 1and 2, with hidden parts represented by broken lines, and shownpositioned on a vehicle axle represented in fragmentary form and byphantom lines;

[0017]FIG. 4 is a top plan view of a steel blank used to form the ABSsensor bracket, but prior to folding the steel to form the bracket, andafter it has been stamped from sheet steel; and

[0018]FIG. 5 is a perspective view, looking generally in the outboarddirection, showing an ABS bracket mounted on an axle section adjacent toa wheel hub tone ring, and further showing in exploded fragmentaryformat an ABS sensor and a retaining sleeve for mounting in the bracket.

[0019] Similar numerals refer to similar parts throughout the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0020] The ABS sensor bracket of the present invention is indicatedgenerally at 10 and is shown in FIGS. 1-3. Bracket 10 preferably isformed from a piece of sheet steel having a thickness of from about 0.06to about 0.15 inches, and preferably about 0.13 inches. A steel blank 50having the configuration and size shown in FIG. 4 is cut from the sheetof steel, preferably by stamping. Bracket 10 then is formed into itsfinal shape by folding steel blank 50 into the configuration shown inFIGS. 1-3, preferably by a multi-stage forming process using a single ormultiple presses.

[0021] More specifically, formed bracket 10 includes a tubular portion11 and a pair of spaced apart rear legs 12 which each extend generallysidewardly downwardly from the tubular portion. Each leg 12 in turn isformed with a rearwardly extending foot 22. Tubular portion 11 is formedinto a continuous circular structure having a continuous opening 15 byjoining lower opposed edges 13 at seam 14, preferably by a resistanceweld (not shown). However, it is understood that lower edges 13 could beleft open or slightly spaced-apart and free of welds, without affectingthe overall inventive concept.

[0022] As best shown in FIGS. 3 and 5, when bracket 10 is positioned onan axle 20, the lowermost portion of the bottom surface of each foot 22,hereinafter referred to as edge 23, contacts the outermost or exteriorsurface of the axle. Bracket 10 is attached to axle 20 preferably usinga MIG weld (not shown), which is well-known in the art and adds a fillermetal at the contact points between each foot edge 23 and axle 20.However, it is understood that other types of welding could be utilizedsuch as TIG welding which would utilize a portion of the materialforming each bracket foot edge 23 and a portion of the material formingaxle 20 at the point where the feet edges contact the axle to create theweld between bracket 10 and the axle.

[0023] An ABS sensor 30 is captured or mounted in bracket 10 in thefollowing manner. A retaining sleeve 31 which is well-known in the artand typically supplied by the ABS sensor manufacturer, is first mountedin opening 15 of bracket 10. Sleeve 31 conventionally is formed ofberyllium copper, and includes a plurality of outwardly and inwardlybiased protuberances 32 and 33, respectively. A plurality of verticallyextending stops 34 are formed along the periphery of the rear end ofretaining sleeve 31. The front end of sleeve 31 thus is pushed into therear end of bracket continuous opening 15 until stops 34 contact therear edge of tubular portion 11. Sleeve 31 preferably is approximatelythe same length as tubular portion 11 and has a slightly smaller outsidediameter than the inside diameter of the tubular portion, and issecurely held therein by an interference fit crated by the outward biasof protuberances 32 bearing against the interior surface of the tubularportion.

[0024] ABS sensor 30, which is cylindrical-shaped and has a lengthsimilar to that of bracket tubular portion 11 and retaining sleeve 31,then can be mounted within bracket 10 and the sleeve. More particularly,ABS sensor 30 has an outside diameter slightly smaller than the insidediameter of sleeve 31, but when pushed into the rear end of sleeve 31 isheld securely therein by an interference fit created by the inward biasof protuberances 33 bearing against the exterior surface of the sensor.An electrical conduit or cable 35 extends from the rear end of sensor 30and electrically connects the sensor to the ABS electronic control unit(not shown) in a well-known manner. More specifically, ABS sensor 30senses certain movements of teeth 40 on tone ring 41 of wheel hub 42,and relays such information to the electronic control unit which in turnenables control of brake engagement.

[0025] Thus, in accordance with one of the important features of thepresent invention, it clearly can be seen and understood that the designof bracket 10 enables precise positioning of a centerline C of brackettubular portion 11 a certain height from the centerline (not shown) ofaxle 20 to ensure proper vertical disposition of ABS sensor 30 inrelation to wheel hub tone ring teeth 40. Moreover, feet 22, and moreparticularly elongated parallel feet edges 23, contact the curvedperiphery of axle 20 in such a way so as to ensure a parallelself-alignment or squaring of the outboard sensing face (not shown) ofsensor 30 with the inboard faces of tone ring teeth 40 when sufficientnormal pressure is placed on bracket 10 against axle 20 duringinstallation of the bracket. Rearwardly extending feet 22 also providemore flexibility for positioning bracket 10 in various vehicleapplications having different hub and/or spindle configurations, such asthose applications having tapered or stepped spindles.

[0026] It is understood that the configuration and size of bracket 10shown and described herein is intended for use with an axle having anoutside diameter of 5-¾ inches. However, the size of the axle with whichABS sensor bracket 10 of the present invention is utilized does notaffect the overall concept of the present invention, and it iscontemplated that the size and/or shape of bracket 10 could be modifiedfor use with other diameter axles to similarly properly position an ABSsensor on the axle adjacent to a wheel hub tone ring. In addition, it isfurther contemplated that bracket 10 could be configured to have onlyone leg and one foot. For example, if the single foot was wide enough,it could achieve the self-alignment or squaring function in a fashionsimilar to that achieved by dual feet 22 of the preferred embodiment ofthe present invention. It is also contemplated that bracket 10 could beformed of other sturdy materials, and that blanks 50 could be formed bymethods other than stamping, and the folding into the final shape ofbracket 10 could be performed utilizing a different number of processsteps and using different equipment than those described hereinabove asbeing preferred. It is further understood that alternatives for securingbracket 10 to an axle could be utilized, such as employing a band clampon feet 22 instead of welds.

[0027] It is also understood that bracket 10 could be utilized to holdother sensors which perform other functions, such as a vehicle backupsensor, which senses rearward movement of wheel hub tone ring 41 andrelays that information to an alarm which provides an audible sound towarn people of the backing vehicle. Thus, a second one or moreadditional brackets could be mounted on axle 20 in the same manner asABS sensor bracket 10 without affecting the overall concept of thepresent invention.

[0028] Thus, it can be seen that ABS sensor bracket 10 of the presentinvention overcomes the problems associated with prior art ABS sensorbrackets which conventionally utilized either a casting process,extensive machining of heavy metal blocks, or fabrication and welding ofmultiple parts, to produce a lower cost, efficient bracket whichachieves all the enumerated objectives.

[0029] Accordingly, the improved ABS sensor bracket and method ofmanufacture of the present invention is simplified, provides aneffective, safe, inexpensive, and efficient device which achieves all ofthe enumerated objectives, provides for eliminating difficultiesencountered with prior ABS sensor brackets, and solves problems andobtains new results in the art.

[0030] In the foregoing description, certain terms have been used forbrevity, clearness and understanding; but no unnecessary limitations areto be implied therefrom beyond the requirements of the prior art,because such terms are used for descriptive purposes and are intended tobe broadly construed.

[0031] Moreover, the description and illustration of the invention is byway of example, and the scope of the invention is not limited to theexact details shown or described.

[0032] Having now described the features, discoveries and principles ofthe invention, the manner in which the improved ABS sensor bracket isconstructed, arranged and used, the characteristics of the constructionand arrangement, and the advantageous, new and useful results obtained;the new and useful processes, structures, devices, elements,arrangements, parts and combinations are set forth in the appendedclaims.

What is claimed is:
 1. A bracket for positioning sensor means on avehicle axle adjacent to a wheel hub tone ring, said bracket including:a) means for capturing said sensor means; and b) at least one footattached to said capture means for contacting an exterior surface ofsaid axle to ensure proper location of said sensor means on the axleadjacent to said wheel hub tone ring for sensing movement of the tonering.
 2. The bracket of claim 1, in which said bracket is a one-piecestructure.
 3. The bracket of claim 2, in which said bracket is formed ofsteel.
 4. The bracket of claim 1, in which said capture means is atubular portion of said bracket formed with a continuous opening; inwhich a pair of legs each extend generally sidewardly downwardly fromsaid tubular portion; and in which a pair of feet each extend generallysidewardly downwardly and rearwardly from a respective one of said legs.5. The bracket of claim 4, in which a lowermost portion of a bottomsurface of each foot is formed with a contact edge; and in which eachfoot edge is spaced-apart from and parallel to the other one of saidfoot edges.
 6. The bracket of claim 4, in which each of said feet iswelded to an exterior surface of said axle by a MIG weld.
 7. The bracketof claim 4, in which each of said feet is welded to an exterior surfaceof said axle by a TIG weld.
 8. The bracket of claim 4, in which saidbracket is attached to said axle with a band clamp, which captures saidfeet against said axle.
 9. The bracket of claim 1, in which said sensormeans is an anti-lock braking system sensor; and in which said sensorsenses movement of a plurality of teeth formed on said wheel hub tonering.
 10. The bracket of claim 1, in which said sensor means is avehicle back-up sensor; and in which said sensor senses movement of aplurality of teeth formed on said wheel hub tone ring.
 11. A method ofmaking a bracket for mounting sensor means on a vehicle axle adjacent toa wheel hub tone ring, said method including the steps of: a) forming asubstantially flat blank of a robust material having a certain size andconfiguration; b) forming said blank by a plurality of operations into afinal configuration of said bracket.
 12. The method of claim 11, inwhich said robust material is sheet steel having a thickness of fromabout 0.06 to about 0.15 inches.
 13. The method of claim 12, in whichsaid steel has a thickness of about 0.13 inches.
 14. The method of claim11, in which said blank is formed by stamping.
 15. The method of claim 11, in which said blank is formed into said bracket by a plurality offolding operations.
 16. The method of claim 15, in which said foldingoperations are performed on a single press.
 17. The method of claim 15,in which said folding operations are performed on a plurality ofpresses.
 18. The method of claim 11, in which said sensor means is ananti-lock braking system sensor; and in which said sensor sensesmovement of a plurality of teeth formed on said wheel hub tone ring. 19.The method of claim 11, in which said sensor means is a vehicle back-upsensor; and in which said sensor senses movement of a plurality of teethformed on said wheel hub tone ring.
 20. The method of claim 11, in whichsaid vehicle is a heavy-duty vehicle.